Optical Sensor Focus for 3D Printer Feature Height Identification
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Solution Overview
Problem
Three-dimensional object printers using inkjet printheads often experience functionality issues during printing, leading to inaccurately formed object features due to inkjet deficiencies, resulting in scrapped products and inefficient production processes.
Innovation Solution
A system utilizing an optical sensor with a light source and photo detectors in a linear array to measure object feature heights by moving relative to the object, allowing for real-time identification and correction of feature inaccuracies through actuator control and controller operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If inkjet printheads are used to eject material drops during printing, then three-dimensional objects can be formed layer by layer, but inkjet functionality deterioration leads to inaccurate feature formation and product defects
Solution Approach 1:
The optical sensor performs preliminary detection of feature heights during the printing process before the object is complete. This allows early identification of inkjet deficiencies and potential feature inaccuracies, enabling corrective actions to be taken during printing rather than after completion, thereby maintaining both productivity and precision.
Solution Approach 2:
The system implements feedback by continuously monitoring feature heights with the optical sensor and comparing them against target dimensions. When deviations are detected indicating inkjet deterioration, the system can trigger restorative procedures or adjust printing parameters to compensate, ensuring feature accuracy is maintained throughout the printing process.
2Productivity
If printing continues without interruption to maintain productivity, then production efficiency is improved, but undetected feature inaccuracies accumulate leading to scrapped products
Solution Approach 1:
The optical sensor operates continuously during the printing process without requiring interruption of material deposition. The sensor can detect feature heights at various stages of layer formation, allowing continuous monitoring and quality assurance while maintaining uninterrupted printing operations, thus preserving both productivity and reliability.
Solution Approach 2:
The printing system performs self-diagnosis through the optical sensor's continuous monitoring of feature heights. When inkjet deficiencies are detected, the system can automatically trigger restorative procedures or adjust printing parameters without external intervention, ensuring product quality consistency while maintaining continuous production.
3Manufacturing precision
If restorative procedures are applied after printing completion to fix inkjet deficiencies, then feature accuracy can be improved, but production time is significantly increased
Solution Approach 1:
The optical sensor performs preliminary detection of feature heights during the printing process itself, identifying inkjet deficiencies before the printing is complete. This allows restorative procedures to be initiated during printing rather than after completion, significantly reducing or eliminating post-processing time while maintaining feature accuracy.
Solution Approach 2:
By detecting feature height deviations in real-time during printing, the system can immediately address inkjet deficiencies through restorative procedures or parameter adjustments, skipping the lengthy post-processing inspection and correction phase that would otherwise be required, thus reducing total production time.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables real-time detection and correction of feature inaccuracies during printing, improving product yield and printing efficiency by ensuring accurate object formation and reducing the need for post-processing restoration.
Implementation Method 1
A system utilizing an optical sensor with a light source and photo detectors in a linear array to measure object feature heights by moving relative to the object
Implementation Method 2
an optical sensor having at least one light source and a plurality of photo detectors arranged in a linear array
Data Source
AI summary
A three-dimensional object printer generates image data of an object being formed in the printer with an optical sensor and identifies the heights of object features above a substrate on which the object is being formed. A controller operates one or more actuators to move the optical sensor at a plurality of distances above the object to generate image data of the object at a plurality of heights above the object. The controller identifies the distances of the features of the object with reference to the image data generated by the optical sensor and the focal length of the optical sensor.